Beverage maker flow detection logic

ABSTRACT

The water heating flow detection system for a beverage maker includes a heater control logic circuit that controls heating in response to temperature and flow conditions in the beverage maker. A heater control logic circuit receives a temperature detection signal and a flow detection signal, and generates a water heater control signal for controlling operation of one or more water heaters. A flow detection device may be connected to the hot water outlet conduit or the cold water inlet conduit, and may include a magnetic flow detection device. A faucet lever position detection device may also be used to indicate flow through a faucet outlet valve.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a division of application Ser. No. 11/841,142, filedAug. 20, 2007, which is based upon Provisional Application No.60/839,545, filed Aug. 23, 2006.

BACKGROUND OF THE INVENTION

The present invention relates generally to the field of beverage makers,coffee makers, water heaters, and water boilers, and more particularlyrelates to a flow detection logic for a beverage maker.

Certain water boilers, water heaters, coffee makers or the like,hereafter referred as “units,” use a manual faucet or tap to dispensehot water. In these units, the control circuitry that controls heatingof the water does not initiate heating of the water as soon as water isbeing dispensed. These units' control circuits solely rely on detectionof the temperature of the water in the tank to turn the heaters on andoff. In these units, the heaters are turned on only when the detectedwater temperature inside the tank falls below a pre-set limit. As aresult, the control circuitry can not anticipate the need for heatingthe water. The drawback of this approach is that it creates a delaybetween the time when water is being withdrawn, and when the heaters areturned on.

In an attempt to overcome the problem of delay between dispensing of hotwater and heating of water, current units are often equipped with adevice called an “anticipator tube” as is illustrated in FIG. 1, showinga prior art water heating system 10 for a beverage maker unit, whichtypically includes a water tank 12 enclosing an interior chamber 14, anda cold water inlet conduit 16 connected to the water tank, with theanticipator tube 18 connected to the cold water inlet conduit. A hotwater outlet conduit 20 is connected to the water tank and includes amanual hot water faucet outlet valve 22 with a faucet lever 24 foroperating the manual hot water faucet outlet valve. The faucet lever istypically movable between a faucet outlet valve open position and afaucet outlet valve closed position. A temperature measuring device 26is also provided in the tank adjacent to an outlet end of theanticipator tube, so that as cold water is supplied to the water tank,the anticipator tube introduces cold water into the water tank near thetemperature measuring device, lowering the water temperature in thevicinity of the temperature measuring device. One or more heaters 28 areconnected to a heater control logic unit 30 which receives a temperaturesignal from the temperature measuring device, so that when cold water isflowing into the unit to replace water being dispensed from the unit,cold water is directed onto the temperature measuring device toartificially lower its temperature, hence turning the heaters onearlier. The drawbacks of this concept are the following:

First, for this system to be effective, cold water is to be sprayed nearthe temperature measuring device, which is often located at the top ofthe water tank, close to the hot water outlet. As a result, the coldwater introduced at the top of the water tank by the anticipator tubereduces the water outlet temperature, which is not a desired effect.

Second, as the cold water from the anticipator tube mixes with the hotwater around the temperature measuring device, the temperature aroundthe temperature measuring device drops fairly slowly. As a result, itoften takes 15 to 40 seconds of cold water flow from the anticipatortube for the unit's control circuit to turn the heaters on. This delaycauses the overall temperature in the tank to drop more rapidly, andalso increases the overall re-heating time.

Third, the orientation and location of the anticipator tube has to beadjusted so the right amount of cold water is sprayed on the temperaturemeasuring device. Not enough cold water sprayed onto the temperaturemeasuring device would render the water heating system ineffective, andtoo cold water sprayed onto the temperature measuring device much wouldeliminate completely the temperature sensing capabilities of the unitcontrol circuitry, potentially causing over-heating of water in thetank. This adjustment is not only required at the factory, but is alsorequired throughout the life of the product, hence increasing themanufacturing, maintenance and repair costs.

It would therefore be desirable to eliminate these performancedrawbacks. The present invention addresses and solves these and otherproblems associated with heating of water in a beverage maker.

SUMMARY OF THE INVENTION

Briefly, and in general terms, the present invention provides for asystem for detecting fluid flow to or from a beverage makers waterheating system and providing a flow detection signal to the beveragemaker's logic to improve performance of a beverage maker's water heatingsystem. Calculations have shown that detecting the need for reheatingwater in the beverage maker's water heating tank as soon as hot water isdrawn from the tank can improve the production of hot water by 15 to25%. This improved performance increases the value of the product to theend user.

The present invention accordingly provides for a water heating flowdetection system for a beverage maker that includes a heater controllogic circuit that controls heating of water in response to temperatureflow conditions in the beverage maker, so that heating of water in thebeverage maker can be carried out efficiently, as needed. The beveragemaker typically includes a water tank having an interior chamber, a coldwater inlet conduit connected in fluid communication with the interiorchamber for supplying water to the water tank, and a hot water outletconduit connected in fluid communication with the interior chamber fordispensing heated water from the water tank. The hot water outletconduit includes a manual hot water faucet outlet valve having a faucetlever movable between a faucet outlet valve open position and a faucetoutlet valve closed position. Typically the water tank includes one ormore water heaters associated with the water tank for heating water inthe water tank, and a temperature measuring device associated with thewater tank for measuring a water temperature and for generating atemperature detection signal.

According to the present invention, a flow detection device isoperatively connected to the beverage maker for detecting flow in atleast a portion of the beverage maker for generating a flow detectionsignal. In one preferred aspect, an outlet flow detection device may beconnected to the hot water outlet conduit for detecting flow in the hotwater outlet conduit, or an inlet flow detection device may be connectedto the cold water inlet conduit for detecting flow in the cold waterinlet conduit. In another preferred aspect, the flow detection devicemay include a faucet lever position detection device connected to thefaucet lever for detecting whether the faucet outlet valve is in theopen position or the closed position, and generating a faucet leverposition signal indicating flow through the faucet outlet valve when thefaucet outlet valve is in the open position.

In the outlet flow detection device or the inlet flow detection device,the flow detection device may be a magnetic flow detection device thatincludes a flow switch sensor housing including a flow sensor chamberoperatively connected to the hot water outlet conduit, and a magnetretained in the flow sensor chamber and movable within the flow sensorchamber between a non-flow sensing position at a first end of the flowsensor chamber and a flow sensing position at a second end of the flowsensor chamber. The magnet moves to the flow sensing position responsiveto flow within the flow sensor chamber, while a return spring disposedin the flow sensor chamber biases the magnet toward the non-flow sensingposition in the absence of flow within the flow sensor chamber. Amagnetic detection sensor is disposed adjacent to the second end of theflow sensor chamber for detecting the magnet and generating the flowdetection signal when the magnet is in the flow sensing position.

A heater control logic circuit is operatively connected to thetemperature measuring device and the outlet flow detection device forreceiving the temperature detection signal and the flow detectionsignal. The heater control logic circuit is also operatively connectedto the one or more water heaters and generates a water heater controlsignal for controlling operation of the one or more water heatersresponsive to the temperature detection signal and the flow detectionsignal.

The present invention also provides for a method of controlling heatingof water in a beverage maker, including the steps of measuring atemperature of water in the water tank of the beverage maker andgenerating a temperature detection signal indicative of the temperature,and detecting flow in at least a portion of the beverage maker andgenerating a flow detection signal indicative of the flow. A heatercontrol logic circuit receives the temperature detection signal and theflow detection signal, and generates a water heater control signal forcontrolling operation of the one or more water heaters responsive to thetemperature detection signal and the flow detection signal. Flow in atleast a portion of the beverage maker may be detected by a flowdetection device in the hot water outlet conduit or in the cold waterinlet conduit. Flow may also be detected by detecting whether the faucetoutlet valve is in the open position or the closed position, andgenerating a faucet lever position signal indicating flow through thefaucet outlet valve when the faucet outlet valve is in the openposition.

These and other aspects and advantages of the invention will becomeapparent from the following detailed description and the accompanyingdrawings, which illustrate by way of example the features of theinvention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic diagram of a typical prior art beverage makerwater heating system.

FIG. 2 is a schematic diagram of a first embodiment of a water heatingsystem for a beverage maker, according to the present invention.

FIG. 3 is a schematic diagram of a second embodiment of a water heatingsystem for a beverage maker, according to the present invention.

FIG. 4 is a schematic diagram of a third embodiment of a water heatingsystem for a beverage maker, according to the present invention.

FIG. 5 is a graph illustrating the overall benefits of the beveragemaker water heating anticipation method and system according to thepresent invention.

FIG. 6 is a schematic diagram of a flow switch sensor adapted for use asa flow detection device in the system according to the presentinvention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to the drawings, which are provided for purposes ofillustration by way of example, and not by way of limitation, thepresent invention provides a system for detecting fluid flow andproviding a flow detection signal to a beverage maker's logic to improveperformance of a beverage maker's water heating system.

The water heating flow detection system of the invention provides anadditional input signal to the beverage maker's water heating unit'scontrol circuitry to anticipate the need for re-heating. The inputsignal is based on whether or not water is flowing through the waterheating system. This signal can be created by either directly sensingthe water flow by a flow detection device such as a flow switch or aflow meter, for example, or by detecting the position of a manual faucetlever or other flow control valve (e.g. open or closed).

Accordingly, in a first presently preferred embodiment, illustrated inFIG. 2, the present invention provides for a water heating system 40 fora beverage maker including a water tank 42 enclosing an interior chamber44. A cold water inlet conduit 46 is connected in fluid communicationwith the water tank at a cold water inlet port 48 of the water tank, anda hot water outlet conduit 50 having a manual hot water faucet outletvalve 52 is similarly connected in fluid communication with the watertank. The manual hot water faucet outlet valve includes a faucet lever54 for operating the manual hot water faucet outlet valve, which ismovable between a faucet outlet valve open position and a faucet outletvalve closed position (not shown).

A temperature measuring device 56 is mounted within the water tank, andgenerates a temperature detection signal 58 that is received by a heatercontrol logic circuit 60. An outlet flow detection device 62 isconnected to the hot water outlet conduit for detecting flow in the hotwater outlet conduit and generating a flow detection signal 64 that isreceived by the heater control logic circuit. The heater control logiccircuit in turn generates a water heater control signal 66 that isreceived by and that controls the operation of one or more water heaters68 associated with the water tank for heating water in the water tankresponsive to the flow detection signal and the temperature detectionsignal.

Referring to FIG. 3, in a second presently preferred embodiment, thepresent invention provides for a water heating system 70 for a beveragemaker including a water tank 72 having side walls enclosing an interiorchamber 74. A cold water inlet conduit 76 is connected in fluidcommunication with the water tank at a cold water inlet port 78 of thewater tank, and a hot water outlet conduit 80 similarly is connected influid communication with the water tank for supplying heated water fromthe water tank. The hot water outlet conduit includes a manual hot waterfaucet outlet valve 82 having a faucet lever 84 for operating the manualhot water faucet outlet valve. The faucet lever is movable between afaucet outlet valve open position and a faucet outlet valve closedposition (not shown).

A temperature measuring device 86 is also mounted in the water tank forgenerating a temperature detection signal 88 that is received by aheater control logic circuit 90. An inlet flow detection device 92 isalso provided that is connected to the cold water inlet conduit fordetecting flow in the cold water inlet conduit and generating a flowdetection signal 94 that is received by the heater control logiccircuit, which in turn generates a water heater control signal 96responsive to the flow detection signal and the temperature detectionsignal that is received by and that controls the operation of one ormore water heaters 98 associated with the water tank for heating waterin the water tank.

Referring to FIG. 4, in a third presently preferred embodiment, thepresent invention provides for a water heating system 100 for a beveragemaker having a water tank 102 with side walls enclosing an interiorchamber 104, a cold water inlet conduit 106 connected to the water tankat a cold water inlet port 108 of the water tank, and a hot water outletconduit 110 connected to the water tank for supplying heated water fromthe water tank through a manual hot water faucet outlet valve 112. Themanual hot water faucet outlet valve includes a faucet lever 114 foroperating the manual hot water faucet outlet valve, and as isillustrated in FIG. 4, the faucet lever is movable between a faucetoutlet valve open position 113 and a faucet outlet valve closed position115.

A temperature measuring device 116 is mounted in the water tank, andgenerates a temperature detection signal 118 that is received by aheater control logic circuit 120. A faucet lever position detectiondevice or switch 122 is connected to the faucet lever for detectingwhether the faucet outlet valve is in the open position or the closedposition, and for generating a faucet lever position signal 124indicating whether the faucet outlet valve is in the open position orthe closed position. The faucet lever position signal is received by theheater control logic circuit, which in turn generates a water heatercontrol signal 126 received by one or more water heaters 128 associatedwith the water tank for heating water in the water tank, for controllingthe operation of the one or more water heaters, responsive to the faucetlever position signal and the temperature detection signal.

The graph in FIG. 5 illustrates the overall benefits of the anticipationsystem of the present invention. In the example illustrated in FIG. 5, alarge water heating tank was connected to the logic controller (PCB) ofa coffee maker. A flow switch was connected in-line on the cold waterinlet. The flow switch was connected to the coffee maker PCB such thatthe heaters were turned on as soon as the flow switch detected flow. Inthe graph, the line 130 represents water heater tank water temperatureover a period operation of a prior art water heater tank during andafter a server draw (1.5 liters) off a 4.0 liter tank, not using thetemperature anticipation system of the invention. The line 132represents water heater tank water temperature over the same period ofoperation for a water heater system, during and after a server draw (1.5liters) off a 4.0 liter tank, utilizing the temperature anticipationsystem of the invention. It should be readily apparent that by beingable to sense/detect whether or not the unit is flowing, the electroniccontroller of the present invention can turn the heaters on immediatelyto not only increase the overall water temperature of the hot waterdraw, but also to improve significantly the recovery time of the unit.

Various types of flow detection devices may be used in the presentinvention. For example, the flow detection device may be a magnetic flowdetection device 140 illustrated in FIG. 6, including a flow switchsensor housing 142, typically formed of plastic tubing, which defines aflow sensor chamber 144 confining a magnet 146 constructed to be carriedalong within the chamber by water flow through the housing, and movablebetween a non-flow sensing position at a first end 148 of the flowsensor chamber and a flow sensing position at a second end 150 of theflow sensor chamber. When water flows through a conduit 151 and throughthe flow sensor chamber, the magnet is displaced. A magnetic detectionsensor 152 detects the presence or absence of a magnetic field (reedswitch) at the flow sensing position at a second end of the flow sensorchamber, and sends a logic signal 154 (typically a “0” or “1”) to theelectronic circuitry. The magnet is biased to be reset in its “no flow”position with a return spring 156 disposed in the flow sensor chamberand situated between a flow sensor chamber interior flange 158 and anexterior flange 160 on the magnet, although when the magnetic flowswitch sensor is vertically oriented, the magnet may be reset in its “noflow” position by the force of gravity.

It will be apparent from the foregoing that while particular forms ofthe invention have been illustrated and described, various modificationscan be made without departing from the spirit and scope of theinvention. Accordingly, it is not intended that the invention belimited, except as by the appended claims.

1. A water heating flow detection system for a beverage maker, saidbeverage maker including a water tank having an interior chamber, a coldwater inlet conduit connected in fluid communication with the interiorchamber for supplying water to the water tank, a hot water outletconduit connected in fluid communication with the interior chamber forsupplying heated water from the water tank, the hot water outlet conduitincluding a manual hot water faucet outlet valve having a faucet levermovable between a faucet outlet valve open position and a faucet outletvalve closed position, the water heating flow detection systemcomprising: at least one water heater associated with said water tankfor heating water in said water tank; a temperature measuring deviceassociated with said water tank for measuring a temperature of water inthe water tank and generating a temperature detection signal; a flowdetection device operatively connected to said beverage maker fordetecting flow in at least a portion of the beverage maker andgenerating a flow detection signal; and a heater control logic circuitoperatively connected to said temperature measuring device and saidoutlet flow detection device for receiving said temperature detectionsignal and said flow detection signal, said heater control logic circuitoperatively connected to said at least one water heater and generating awater heater control signal for controlling operation of said at leastone water heater responsive to said temperature detection signal andsaid flow detection signal.
 2. The water heating flow detection systemof claim 1, wherein said flow detection device comprises an outlet flowdetection device connected to the hot water outlet conduit for detectingflow in the hot water outlet conduit.
 3. The water heating flowdetection system of claim 2, wherein said outlet flow detection devicecomprises a magnetic flow detection device.
 4. The water heating flowdetection system of claim 3, wherein said magnetic flow detection devicecomprises: a flow switch sensor housing including a flow sensor chamberoperatively connected to the hot water outlet conduit; a magnet retainedin said flow sensor chamber and movable within said flow sensor chamberbetween a non-flow sensing position at a first end of the flow sensorchamber and a flow sensing position at a second end of the flow sensorchamber, said magnet moving to said flow sensing position responsive toflow within said flow sensor chamber; a return spring disposed in saidflow sensor chamber operative to bias said magnet toward said non-flowsensing position in the absence of flow within said flow sensor chamber;and a magnetic detection sensor disposed adjacent to said second end ofthe flow sensor chamber for detecting said magnet and generating saidflow detection signal when said magnet is in said flow sensing position.5. The water heating flow detection system of claim 1, wherein said flowdetection device comprises an inlet flow detection device connected tothe cold water inlet conduit for detecting flow in the cold water inletconduit.
 6. The water heating flow detection system of claim 5, whereinsaid inlet flow detection device comprises a magnetic flow detectiondevice.
 7. The water heating flow detection system of claim 6, whereinsaid magnetic flow detection device comprises: a flow switch sensorhousing including a flow sensor chamber operatively connected to thecold water inlet conduit; a magnet retained in said flow sensor chamberand movable within said flow sensor chamber between a non-flow sensingposition at a first end of the flow sensor chamber and a flow sensingposition at a second end of the flow sensor chamber, said magnet movingto said flow sensing position responsive to flow within said flow sensorchamber; a return spring disposed in said flow sensor chamber operativeto bias said magnet toward said non-flow sensing position in the absenceof flow within said flow sensor chamber; and a magnetic detection sensordisposed adjacent to said second end of the flow sensor chamber fordetecting said magnet and generating said flow detection signal whensaid magnet is in said flow sensing position.
 8. The water heating flowdetection system of claim 1, wherein said flow detection devicecomprises a faucet lever position detection device connected to thefaucet lever for detecting whether the faucet outlet valve is in theopen position or the closed position, and generating a faucet leverposition signal indicating flow through the faucet outlet valve when thefaucet outlet valve is in the open position.
 9. In combination with abeverage maker including a water tank having an interior chamber, a coldwater inlet conduit connected in fluid communication with the interiorchamber for supplying water to the water tank, a hot water outletconduit connected in fluid communication with the interior chamber forsupplying heated water from the water tank, the hot water outlet conduitincluding a manual hot water faucet outlet valve having a faucet levermovable between a faucet outlet valve open position and a faucet outletvalve closed position, at least one water heater associated with saidwater tank for heating water in said water tank, a temperature measuringdevice associated with said water tank for generating a temperaturedetection signal, a water heating flow detection system comprising: aflow detection device operatively connected to said beverage maker fordetecting flow in at least a portion of the beverage maker forgenerating a flow detection signal; and a heater control logic circuitoperatively connected to said temperature measuring device and saidoutlet flow detection device for receiving said temperature detectionsignal and said flow detection signal, and said heater control logiccircuit operatively connected to said at least one water heater andgenerating a water heater control signal for controlling operation ofsaid at least one water heater responsive to said temperature detectionsignal and said flow detection signal.
 10. The combination of claim 9,wherein said flow detection device comprises an outlet flow detectiondevice connected to the hot water outlet conduit for detecting flow inthe hot water outlet conduit.
 11. The combination of claim 10, whereinsaid outlet flow detection device comprises a magnetic flow detectiondevice.
 12. The combination of claim 11, wherein said magnetic flowdetection device comprises: a flow switch sensor housing including aflow sensor chamber operatively connected to the hot water outletconduit; a magnet retained in said flow sensor chamber and movablewithin said flow sensor chamber between a non-flow sensing position at afirst end of the flow sensor chamber and a flow sensing position at asecond end of the flow sensor chamber, said magnet moving to said flowsensing position responsive to flow within said flow sensor chamber; areturn spring disposed in said flow sensor chamber operative to biassaid magnet toward said non-flow sensing position in the absence of flowwithin said flow sensor chamber; and a magnetic detection sensordisposed adjacent to said second end of the flow sensor chamber fordetecting said magnet and generating said flow detection signal whensaid magnet is in said flow sensing position.
 13. The combination ofclaim 9, wherein said flow detection device comprises an inlet flowdetection device connected to the cold water inlet conduit for detectingflow in the cold water inlet conduit.
 14. The combination of claim 13,wherein said inlet flow detection device comprises a magnetic flowdetection device.
 15. The combination of claim 14, wherein said magneticflow detection device comprises: a flow switch sensor housing includinga flow sensor chamber operatively connected to the cold water inletconduit; a magnet retained in said flow sensor chamber and movablewithin said flow sensor chamber between a non-flow sensing position at afirst end of the flow sensor chamber and a flow sensing position at asecond end of the flow sensor chamber, said magnet moving to said flowsensing position responsive to flow within said flow sensor chamber; areturn spring disposed in said flow sensor chamber operative to biassaid magnet toward said non-flow sensing position in the absence of flowwithin said flow sensor chamber; and a magnetic detection sensordisposed adjacent to said second end of the flow sensor chamber fordetecting said magnet and generating said flow detection signal whensaid magnet is in said flow sensing position.
 16. The combination ofclaim 9, wherein said flow detection device comprises a faucet leverposition detection device connected to the faucet lever for detectingwhether the faucet outlet valve is in the open position or the closedposition, and generating a faucet lever position signal indicating flowthrough the faucet outlet valve when the faucet outlet valve is in theopen position.